PRESS WORKING OPERATIONS(SHEET METAL)

PRESS WORKING OPERATIONS (SHEET METAL)

CUTTING

BENDING

FORMING

DRAWING

BLANKING

BENDING

STRETCH FLANGING

CYLINDRICAL CUP DRAWING RECTANGULAR SHELL DRAWING

IRREGULAR SHAPE DRAWING

PIERCING

FLANGING

SHRINK FLANGING

NOTCHING

HEMMING

REVERSE FLANGING

TRIMMING

HOLE FLANGING

LANCING

Embossing/ Form Beads

JOGGLE

THEORY OF CUTTING
When cutting sheet metal in a die the forces applied to the sheet by the punch and die are basically shear forces, that is, equal and opposite forces spaced at a small distance apart on the metal and produce the cutting. The cutting or separation of the sheet metal is effected through the following stages of shearing Roll over Penetration Fracture From both punch side and Die side simultaneously The spacing or the small distance of the two shearing planes is called clearance.It will be generally about 8 - 10% of metal thickness for MS Sheets.

SHEET METAL CUTTING TERMINOLOGY

VARIOUS CUTTING OPERATIONS

BLANKING It is the operation of cutting or shearing a piece out of sheet to a predetermined contour It is the operation of producing the holes of round or contoured shape in the blanks or in formed parts. In Notching operation a small piece or pieces of metal are removed from the edges/ corners of a Strip or a Blank It is the operation of cutting off the excess metal after the Drawing or Forming operation It is the operation of slitting on three sides and opening out by bending the lug about an axis on the uncut fourth side with in the blank.

PIERCING

NOTCHING

TRIMMING

LANCING

THEORY OF BENDING AND SPRING BACK

BENDING Bending is the process of folding a sheet about a straight line axis which lies in the neutral plane. Bends are made in sheet metal to gain rigidity, to produce a part of desired shape & perform a particular function etc. The cross section of the bend inward from neutral axis is in compression, outward from neutral axis is in tension as shown in the fig. SPRING BACK During bending the metal nearer to the neutral axis is stressed to the values below the elastic limit.This phenomenon creates a narrow elastic band on both sides of the neutral axis.The metal further away from the neutral axis is stressed beyond the yield strength and is plastically deformed and permanently set. When the bending force on the metal is released the elastic band tries to return to the original flat condition but cannot return fully due to the restrictions of the plastically deformed zones . Some slight return does occur as the elastic and plastic zones come to an equilibrium and this return is known as spring back. The amount of spring back mainly depends on the ratio of bending radius to stock thickness. Spring back can be reduced by over bending, Bottoming or stretch bending.

VARIOUS BENDING OPERATIONS

SIMLPE BENDING The operation of Folding the sheet about a straight-line axis is called simple bending

FLANGING

It is similar to above in which the height of bend is shorter compared to the overall size of the part. It strengthens the edges of sheet metal parts It provides flanges required for assembling parts by spot welding or any other joining processes. Hemming is an operation in which the edge 0 of a component gets folded by 180 . It improves the rigidity of the edge It facilitates joining of two parts as in the case of Bonnet assy. /Door assy.

HEMMING

DESIGN CONSIDERATIONS FOR BENDING

Radius of bend T Minimum height of bend 3T

Relief Notches for bend

DESIGN CONSIDERATIONS FOR HEMMING

Where appropriate provide an offset To minimise area of fitting To give additional rigidity to inner panel To reduce potential assembly distortion

Height of flange after 0 +/- 1.0 90 flanging = 9.0 ( except at corners and feature lines)

Maximum permissible radius of bend 0 during 90 flanging = 0.5T Preferred radius of bend during 900 flanging = 0 (or as minimum as possible)

THEORY OF FORMING
Forming is the process in which the shape of the punch and die is directly reproduced in the metal with little or no metal flow. Forming, Bending or drawing actions may be combined in a die and is classified as Form die or Draw die depending on the dominant action of process The decision to use a form die instead of a Draw die will depend largely on the complexity of the shape & geometrical criteria. The use of draw die may be indicated, if the form die would cause the metal to tear because of excessive tensile strain(stretch) or form objectionable wrinkles because of excess crowding of metal etc defects.

VARIOUS TYPES OF FORMING OPERATIONS

In stretch flanging tensile strain increases from zero at the flange break line (axis of bending) to a maximum at the flange edge. For that reason any tearing will start from the flange edge. The amount of tensile strain increases with increasing forming angles and increasing flanging heights

STRETCH FLANGING

SHRINK FLANGING

In shrink flanging, the tendency to wrinkle increases from zero at the flange break line to a maximum at the flange edge.

REVERSE FLANGING

Reverse flanging is the combination of stretch flanging and shrink flanging

It is the process of forming a flange around a hole

HOLE FLANGING BEADS

Beads are long narrow depressions embossed in the sheet metal for stiffening purposes It is a stepped surface provided at lap joint.

JOGGLE

VARIOUS TYPES OF BEADS

ANGULAR These are used to stiffen the flat BEADS areas in large automotive panels V-BEADS These are used to stiffen the flat areas of small and medium size automotive panels This is similar to above v-bead but flat at the tip These are commonly used for small parts These are generally used in draw dies for controlling flow of material. These are used to provide rigidity and maintain accuracy in angle of bend.

FLAT V-BEADS

ROUND BEADS BEAKS

DESIGN CONSIDERATIONS FOR BEADS

ANGULAR BEADS

V-BEADS

BEAKS

THEORY OF DRAWING
Drawing is a process in which the punch causes a flat , precut metal blank in to the die cavity to assume the shape of seamless hollow vessel without excessive wrinkling, thinning, or fracturing. METAL FLOW IN DRAWING PROCESS when the punch of draw die forces a portion of metal blank through the bore of draw ring, different forces such as radial tension, circumfrential compression and bending & frictional forces come in to action as shown in the fig.These forces cause a complicated plastic flow of the material in the blank. The volume and the thickness of the component remain constant and the final shape of the cup will be similar to contour of the punch. The progressive stages of cupping are schematically shown in fig. After a small stroke of the punch, cupping stage A, the metal elements 2, 3, 4, & 5 of the blank move radially toward the center of the blank. The flow of these elements go on till the final stage C of the cup is reached. Thus by the end of the draw of the cup area 1 is unchanged in shape and size in the bottom of the cup. The areas 2,3 & 4 change from the shape of angular segments to longer parallel-sided shapes and area 5 also changed in its size and shape. Due to this metal flow phenomena in Drawing operation, Blank holding pressure is to be applied on the blank in such a way that the metal flow will be a controlled one so as to avoid wrinkling, tearing, thinning etc.

DESIGN CONSIDERATIONS FOR CYLINDRICAL CUP DRAWING

Empirical Rule to decide required no. of Draws for Cylindrical cup (Where h = inside height of shell d = Mean dia. Of shell) If =h/d No. of Draws Up to 0.75 --------- 1 0.75 -- 1.5 --------- 2 1.5 -- 3.0 --------3 3.0 -- 4.5 --------4 Drawing Force for Cylindrical Cup Fd = d t (Su + Sy)/2 Kg. (Fd) Where d = Punch diameter (mm.) 2 Su = Ultimate Tensile strength (Kg/mm ) 2 Sy = Yield strength (Kg/mm ) T = Thickness of sheet. (mm.) Fb = 1/3 of Drawing force(Approx.) Punch Radius = Die radius = 5t 6t

Blank Holder Force(Fb) Empirical Rule for Punch and Die radii.

DESIGN CONSIDERATIONS FOR RECTANGULAR SHELL DRAWING

Empirical Formulae to decide required no. of Draws for Rectangular shell (Where h = inside height shell r = Corner radius Of shell) Drawing Force Rectangular Shell (Fr) If =h/r No. of Draws Up to 7 --------1 7 -13 --------- 2 13 -- 18 --------- 3 18 -- 24 --------- 4 Fr = t Su (2r + C1+L C2 ) Kg.

Where 2 Su = Ultimate Tensile strength (Kg/mm ) T = Thickness of sheet. (mm.) r = Corner radius Of shell. (mm.) L = Total length of straight sides of rectangular shell C1 = 0.5 2(lower values for shallow draw Higher values for h/r > 0 C2 = 0.2 0.3 ( For easy to sever Draw Conditions)

DESIGN CONSIDERATIONS FOR IRREGULAR SHAPE DRAWING

Empirical Formulae to If e% < 5 , Part can be produced by Forming analyze the formability If 5 < e% < 30 , Part requires Draw of Irregular shaped If e% > 30 , Part cannot be formed shells If e% > 5 Wrinkles tend to be shown Where e% = Percentage of elongation = (L L0) x 100 L0 = Blank length before forming L = Blank length after forming e% = Difference in percentage of elongation between neighboring sections Draft angle on draw panel wall = 20 Min. Maximum permissible material thinning = 10% Material utilization Target = 70% and above Drawn corners to be achieved in one Draw

General guide lines related to Drawing Operation